BENDIX SD-13-4785 User Manual

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Page 1

Bendix® EC-15™ AntiLock Controller Assembly

SD-13-4785

MOUNTING

HOLES (4)

FIGURE 1 - EC-15™ ELECTRONIC CONTROLLER

DESCRIPTION

GENERAL

Bendix antilock systems utilizing the EC-15™ electronic controller assembly provide full vehicle, wheel control braking for buses, trucks, and truck tractors. By minimizing the potential of “brake lock-up” on all wheels during aggressive braking the vehicle retains a high degree of stability and steerability , and in most cases vehicle stopping distance is reduced.

In order to provide full vehicle, wheel control braking, the EC-15™ controller assembly is used in combination with the following components:

- Four, individual wheel speed sensors

- Four, air pressure modulator valves

- Antilock condition lamp (dash mounted)

DIAGNOSTICS

WINDOW DISPLAY

PHYSICAL

The EC-15™ controller electronics, that regulate the function of the antilock system, are contained in a die cast aluminum housing and are environmentally protected. The metal housing, coupled with the design of the digital electronics, is intended to provide a high degree of protection from radio and electromagnetic interference.

A diagnostics display window with 9 light emitting diodes (LEDs) and a magnetically actuated reset switch is incorporated in the housing for troubleshooting and diagnostic purposes.

Two types of electrical connectors are currently used to connect the EC-15™ controller assembly to the antilock system components; a single, 30 pin, Packard Electric, 150 series “Metri-pack” or a pair of 14 pin, Deutsch, HID 30 series connectors.

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SERVICE

ACTUATOR

REAR AXLE

™

CR-15

ASSEMBLY

™

EC-15

CONTROLLER

TANDEM AXLE

ANTILOCK

RELAY

™

AR-1

SERIAL LINK

RELAY

DASH LAMP

CONTROL

RETARDER

™

M-21

SERVICE

BRAKE VALVE

QUICK

SENSOR

WHEEL SPEED

EXCITER (4)

RELEASE VALVE

(4)

SERVICE

FRONT AXLE

CHAMBER

MODULATOR

FIGURE 2 - EC-15™/CR-15™ ANTILOCK SYSTEM

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PACKARD 30 PIN

CONNECTOR

FIGURE 3 - EC-15™ CONTROLLER AND CONNECTOR STYLES

DEUTSCH 14 PIN

CONNECTORS

MOUNTING

The EC-15™ controller is available in two different mounting styles. One model is designed to be mounted on an antilock relay valve such as the AR-1™ valve (see Service Data Sheet SD-13-4795). The AR-1™ valve is a modiﬁ ed version of the R-12® relay valve. When the EC-15™ controller is mounted on an antilock relay valve the resulting assembly receives a different designation. For example when the EC-15™ antilock controller is mounted on the AR-1™ valve the resulting assembly is known as a CR-15™ antilock controller relay. The other EC-15

™

controller model is intended for bracket mounting to a frame member and is not attached to an antilock relay valve.

CONTROLLER INPUTS/OUTPUTS

The EC-15™ controller receives information from several components in the antilock system and, based on these inputs, issues commands or delivers information. Some portions of the EC-15™ controller both receive and deliver commands and information.

INPUTS

Wheel speed information is provided to the EC-15™ controller via a wiring harness from individual wheel speed sensors located at or in the vehicle wheels. Working in conjunction with an exciter or tone ring, wheel speed sensors provide information to the EC-15™ controller in the form of an AC signal which varies in voltage and frequency as the speed of the wheel increases or decreases. The

™

EC-15

controller is designed to receive wheel speed information, from various wheel speed sensor models, at the rate of 100 pulses per wheel revolution. The EC-15™ controller is able to simultaneously receive, and individually interpret, speed signals from four wheel speed sensors.

Vehicle power is supplied to the EC-15™ controller from the ignition switch through a fuse or circuit breaker. The electrical ground for the EC-15™ controller is the vehicle chassis.

OUTPUTS

Modulators, like the Bendix

M-21™, are the means by which the EC-15™ antilock controller is able to modify driver applied air pressure to the service brakes. The modulator is an electrically controlled air valve that is located near

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AR-1

FIGURE 4 - EC-15™ CONTROLLER MOUNTED ON AN AR-1™ VALVE

™

ANTILOCK

RELAY VALVE

EC-15™

ELECTRONIC

CONTROLLER

the service actuator(s) it controls and is the last air valve through which air passes on its way to the brake actuator. A wiring harness connects the modulator to the EC-15™ antilock controller. Solenoid valves contained in the modulator provide the electrical interface between the EC-15™ controller electronics and the air brake system. The EC-15™ controller is able to simultaneous and independently control four individual modulator assemblies.

A dash light and its electrical relay is connected to, and controlled by , the EC-15™ controller and serves as a means of advising the driver of the condition of the antilock system. A connection to the engine or transmission retarder is provided on the EC-15™ controller which allows the EC-15™ controller to temporarily “disable” the retarder during certain modes of operation. While the EC-15™ controller is capable of this function, and connections are provided, it is not always used. Use of the retarder disable function is not essential but highly recommended for vehicles equipped with a retarder.

The data link function enables the EC-15™ controller to “report” its operating condition to a specialized, external computer in response to certain commands it receives. The EC-15™ controller data link conﬁ guration conforms to S.A.E. standard J1708 and the protocol, or coded language used, conforms to S.A.E. standard J1587. There are two connections to the EC-15™ controller devoted to the data link. While the EC-15™ controller is capable of this function, and connections are provided, it is not always used. Use of the data link is not essential for the EC-15™ controller to be functional.

OPERATION

GENERAL

The Bendix® EC-15™ antilock controller system provides individual wheel control by using a wheel speed sensor and modulator at each wheel. By monitoring the rate of deceleration during braking, and subsequently adjusting the brake application pressure at each wheel, the EC-15™ controller is able to provide improved braking between the vehicle tire and the road surface it is on, while maintaining vehicle stability.

The rear axle brakes are controlled completely independent of each other and therefore brake application pressure at an individual wheel is adjusted solely on the basis of its behavior on the road surface on which it is traveling. While each steering axle brake is under the control of an individual modulator, the EC-15™ controller does not treat these brakes totally independent of each other. The EC-15™ controller utilizes a modiﬁ ed individual control philosophy for the steering axle brakes. This is done in order to minimize “steering wheel pull” in the event each wheel is traveling on a different road surface (e.g.; ice close to the curb and a dry crown). Essentially the EC-15™ controller controls the braking force differences between the two brakes. The wheel on dry pavement is initially given less braking force and is brought up to optimum during the stop, while the wheel on ice attempts to maintain optimum braking during the entire stop.

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WS-20

SENSOR

™

SPEED

EXCITER RING

(100) TOOTH

HUB ASSEMBLY

WS-20™ ANGLED

SENSOR

WS-20

™

STRAIGHT

SENSOR

FIGURE 5 - WS-20™ WHEEL SPEED SENSORS

In the case of vehicles equipped with tandem rear axles (6x2, 6x4), the wheel speed sensors are installed at the wheels on the axle that is most likely to lose traction ﬁ rst. A single modulator controls both curb side brakes on the tandem, and another modulator controls both brakes on the driver’s side of the tandem. With this arrangement of the speed sensors and modulators, both brakes on one side of the tandem are treated as one since they will most likely be on the same type of road surface. (Refer to ﬁ gure 2)

NON-ANTILOCK BRAKE APPLICATION

During normal braking, air pressure from the brake valve enters the control port of the service relay valve (either an antilock or standard relay). The service relay delivers air to, and through, the antilock modulator located near the braked wheel, and into the brake actuator. The service brakes are thus applied. If the wheel sensors do not detect an impending wheel lock up, the EC-15™ controller does not initiate any corrective action and the vehicle comes to a stop in a normal fashion.

DEUTSCH

CONNECTOR

PACKARD

CONNECTOR

ANTILOCK CONTROLLED BRAKE APPLICATION SYSTEM FULLY OPERATIONAL

If a service brake application is made and the wheel speed sensors detect an impending wheel lockup, the EC-15™ controller will immediately begin modiﬁ cation of the brake application using the antilock modulator(s) at the affected wheel(s).

Solenoid valves contained in the modulator are energized and de-energized by the EC-15™ controller in order to modify the brake application. When a solenoid coil is energized its shuttle moves, and depending upon the function of the speciﬁ c solenoid, it either opens or closes, thereby causing the exhaust or reapplication of air pressure to the brake actuator. The solenoids in each modulator are controlled independently by the EC-15™ controller. By opening and closing the solenoid valves in the appropriate modulator, the EC-15™ controller is actually simulating what the driver does when he “pumps the brakes”. It must be remembered however that unlike the driver, the EC-15™ controller is able to “pump” each brake on the vehicle independently and with far greater speed and accuracy.

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SUPPLY

SOLENOID

CONNECTOR

SUPPLY

MOUNTING

HOLES

EXHAUST

FIGURE 5 - M-21™ MODULATOR

ANTILOCK SYSTEM OPERATION COMPONENT FAILURE

The Bendix® EC-15™ controller handles equipment failure using a conservative fail-safe philosophy. Any single electrical failure of a component devoted to antilock braking, results in simultaneous illumination of the antilock condition lamp on the dash, a disabling of all or part of the antilock system, and reversion to standard braking on wheels no longer under the control of antilock. When coping with wheel equipment (modulator or wheel speed sensor/ exciter) failure, the EC-15™ controller divides and separates the brakes diagonally. For example; if the modulator at the right front wheel has a broken wire lead, the EC-15™ controller disables the antilock function for BOTH the right front and left rear wheels. The antilock will continue to function on the left front and right rear wheels and will remain under the control of the EC-15™ controller. (Note: Right and left, front and rear are determined from the driver’s seat. Left front is therefore the corner closest to the driver). Depending upon the type of failure and its position of occurrence the EC-15™ controller either disables all, or only a portion, of the antilock system. A power or controller failure, for instance, will result in complete disabling of the antilock system and reversion to standard braking on all wheels. Two or more failures, regardless of their position of occurrence, will also result in the disabling of the entire system. With the failed component approach described, the vehicle will retain improved braking stability after a

DELIVERY

single failure. It should be remembered that the driver will be advised of the degraded antilock operation via the dash lamp and that standard air braking will still be available on those brakes where the antilock has been disabled by the EC-15™ controller.

ANTILOCK WIRING

The wires that carry information and power into and out of the EC-15™ controller are generally grouped and terminate at a connector. The wire groups or wire harnesses along with the connectors are most often specified and or supplied by the vehicle manufacturer. Two examples of the connectors used on the EC-15™ controller are illustrated in ﬁ gures 7 & 8. The wiring harnesses and connectors are weather proof and the wires that enter the connector are sealed to the connector. The wire gauge used in the wire harnesses is speciﬁ c to the task performed.

When diagnosing wiring in the antilock system the following general rules apply and should be followed where

applicable:

1. It is generally advisable to replace a wire harness rather than repair individual wires in the harness. If a splice repair must be made, it is important that the splice be properly soldered with a rosin ﬂ ux (not acid based ﬂ ux) and made water proof.

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2. Do not pierce wire insulation when testing. Check for power, ground or continuity by disconnecting the connector and testing the individual pins or sockets in the connector.

3. Always check the vehicle hand book for wire and connector identiﬁ cation. Individual wire identiﬁ cation will differ depending upon the type of connectors in use, the vehicle manufacturer, and the system features in use.

4. While the retarder disable and serial link connections (3 total) are present on all EC-15 not always used.

™

controllers they are

PREVENTATIVE MAINTENANCE

Every 3 months; 25,000 miles; or 900 operating hours,

1. Check all wiring and connectors to ensure they are secure and free from visible damage.

2. Although the EC-15™ controller incorporates a self check diagnostics, the LED display should be inspected to ensure that they are functional. With the vehicle ignition on, a magnet (800 gauss; capable of picking up 3 ounces) held to the LED reset switch should cause all of the LED’s to illuminate. If one or more of the LED’s DO NOT ILLUMINA TE and the antilock condition lamp on the dash indicates the system is functioning properly, the non-illuminated LED(s) should be noted for future reference. Although the diagnostic capabilities will be limited, the system will continue to function as designed.

3. Road test the vehicle by making antilock stop from a vehicle speed of 20 miles per hour. When an antilock stop is made, the modulator solenoids pulsate and an audible burst of air can be heard from outside of the cab. The wheels should not enter a prolonged “lock” condition.

WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO A VOID PERSONAL INJURY OR DEATH:

When working on or around a vehicle, the following general precautions should be observed at all times.

1. Park the vehicle on a level surface, apply the

parking brakes, and always block the wheels. Always wear safety glasses.

2. Stop the engine and remove ignition key when

working under or around the vehicle. When working in the engine compartment, the engine should be shut off and the ignition key should be removed. Where circumstances require that the engine be in operation, EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components.

3. Do not attempt to install, remove, disassemble

or assemble a component until you have read and thoroughly understand the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.

4. If the work is being performed on the vehicle’s air brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with an AD-IS® air dryer system or a dryer reservoir module, be sure to drain the purge reservoir.

5. Following the vehicle manufacturer’s recommended procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle.

6. Never exceed manufacturer’s recommended pressures.

7. Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted.

8. Use only genuine Bendix® replacement parts, components and kits. Replacement hardware, tubing, hose, ﬁ ttings, etc. must be of equivalent size, type and strength as original equipment and be designed speciﬁ cally for such applications and systems.

9. Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless speciﬁ cally stated and approved by the vehicle and component manufacturer.

10. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.

11. For vehicles with Antilock Traction Control (ATC), the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving.

REMOVING THE EC-15™ CONTROLLER ASSEMBLY

EC-15™ CONTROLLER MOUNTED ON ANTILOCK RELAY VALVE

1. Identify and remove all air lines connected to the unit.

2. Disconnect the electrical connector(s) from the EC-15™

controller.

3. Note and mark the mounting position of the controller/

relay valve assembly on the vehicle. Loosen, remove and save the nuts on the mounting hardware that attaches the controller relay assembly bracket to the vehicle. Remove the relay valve and EC-15™ controller assembly from the vehicle.

4. Remove as much contamination as possible from

the exterior of the assembly making sure to keep the contamination away from the open ports.

5. Note and mark the position of the EC-15™ controller

relative to the antilock relay valve. Remove and retain the four cap screws that secure the EC-15™ controller to the antilock relay valve. Carefully separate the EC-15™ controller from the antilock relay valve making certain

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REAR

CONNECTOR 2

DEUTSCH CONNECTORSVEHICLE RIGHT FRONT

FRONT

CONNECTOR 1

CONNECTOR 2

TERMINAL TERMINAL CONNECTION

1J POWER

1K DASH LAMP (RELAY)

1P GROUND

™

EC-15

1N LEFT FRONT MODULATOR EXHAUST

1E LEFT FRONT MODULATOR HOLD

1M LEFT FRONT MODULATOR SOURCE

1F LEFT FRONT SPEED SIGNAL

CONTROLLER

1G LEFT FRONT SPEED SIGNAL RETURN

1B RETARDER DISABLE

™

M-21

MODULATOR

CONNECTOR 1

1C RIGHT FRONT MODULATOR EXHAUST

1A RIGHT FRONT MODULATOR HOLD

1D RIGHT FRONT MODULATOR SOURCE

1H RIGHT FRONT SPEED SIGNAL

1L RIGHT FRONT SPEED SIGNAL RETURN

2K LEFT REAR SPEED SIGNAL

2G LEFT REAR SPEED SIGNAL RETURN

2A LEFT REAR MODULATOR EXHAUST

2C LEFT REAR MODULATOR HOLD

2D LEFT REAR MODULATOR SOURCE

2M RIGHT REAR SPEED SIGNAL

2L RIGHT REAR SPEED SIGNAL RETURN

2E RIGHT REAR MODULATOR EXHAUST

2N RIGHT REAR MODULATOR HOLD

2F RIGHT REAR MODULATOR SOURCE

2B SERIAL A

2H SERIAL B

VEHICLE LEFT REAR

RELAY

SPEED SENSOR

CONTROL

DASH LAMP

RETARDER

FIGURE 7 - WIRING SCHEMATIC FOR EC-15™ CONTROLLER WITH DEUTSCH CONNECTORS

™

HOLD

SOURCE

CONNECTOR ON M-21

EXHAUST

MODULATOR

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PACKARD CONNECTORVEHICLE RIGHT FRONT

TERMINAL TERMINAL CONNECTION

LINK

SERIAL

1K & 2K POWER

3F DASH LAMP (RELAY)

1A & 2A GROUND

2F LEFT FRONT MODULATOR EXHAUST

2G LEFT FRONT MODULATOR HOLD

1G LEFT FRONT MODULATOR SOURCE

3J LEFT FRONT SPEED SIGNAL

3H LEFT FRONT SPEED SIGNAL RETURN

3G RETARDER DISABLE

™

M-21

1H RIGHT FRONT MODULATOR EXHAUST

1J RIGHT FRONT MODULATOR HOLD

1F RIGHT FRONT MODULATOR SOURCE

MODULATOR

2H RIGHT FRONT SPEED SIGNAL

3K RIGHT FRONT SPEED SIGNAL RETURN

3E LEFT REAR SPEED SIGNAL

2C LEFT REAR SPEED SIGNAL RETURN

1B LEFT REAR MODULATOR EXHAUST

1C LEFT REAR MODULATOR HOLD

1D LEFT REAR MODULATOR SOURCE

3D RIGHT REAR SPEED SIGNAL

3C RIGHT REAR SPEED SIGNAL RETURN

2D RIGHT REAR MODULATOR EXHAUST

2E RIGHT REAR MODULATOR HOLD

1E RIGHT REAR MODULATOR SOURCE

3A SERIAL A

3B SERIAL B

2B NOT USED

2J NOT USED

VEHICLE LEFT REAR

RELAY

SPEED SENSOR

POWER

CONTROL

RETARDER

FIGURE 9 - WIRING SCHEMATIC FOR EC-15™ CONTROLLER WITH PACKARD CONNECTOR

™

HOLD

SOURCE

CONNECTOR ON M-21

EXHAUST

MODULATOR

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not to damage the gasket between the two components. Peel the gasket from the EC-15™ controller or antilock relay valve and retain for reuse. Note: Use a new gasket if damaged during removal or if a new gasket is immediately available.

™

BRACKET MOUNTED EC-15

1. Disconnect the electrical connector(s) from the EC-15

CONTROLLER

™

controller.

2. Note and mark the mounting position of the EC-15

™

controller on the vehicle. Loosen, remove and save the nuts on the mounting hardware that attaches the EC-15™ controller bracket to the vehicle. Remove the EC-15™ controller and bracket from the vehicle.

3. Remove and retain the four cap screws that secure the EC-15™ controller to the bracket. Separate the EC-15™ controller from the bracket.

INSTALLING THE EC-15™ CONTROLLER ASSEMBLY

EC-15™ CONTROLLER MOUNTED ON ANTILOCK RELAY VALVE

1. After noting the relationship of the positioning marks made prior to disassembly, position the gasket on the EC-15™ controller then secure the EC-15™ controller to the antilock relay valve using the four cap screws. Torque the cap screws to 50-80 lbs. in.

2. Mount the assembled EC-15™ controller and antilock relay valve on the vehicle and orient it in the position marked prior to removal.

3. Reconnect all air lines to the assembly.

4. Reconnect the electrical connector(s) to the EC-15™ controller.

5. Test the antilock relay valve for operation and leakage prior to placing the vehicle in service.

6. Perform the “Initial Start-up Procedure” in the TROUBLESHOOTING section to assure proper antilock system operation.

BRACKET MOUNTED EC-15™ CONTROLLER

1. Secure the EC-15™ controller to its bracket using the four cap screws. Torque the cap screws to 50-80 lbs. in.

2. After noting the positioning marks, mount the EC-15 controller on the vehicle using the mounting hardware retained during removal.

3. Connect the electrical connector(s) to the EC-15 controller.

™

4. Perform the “Initial Start-up Procedure” in the TROUBLESHOOTING section to assure proper antilock system operation.

DIAGNOSING AND LOCATING A SYSTEM PROBLEM

GENERAL

The EC-15™ controller contains self test and diagnostic circuitry that continuously checks for proper operation of the entire antilock system including wiring continuity . A dash lamp, controlled by the EC-15™ controller, advises the driver of the condition of the entire antilock system. The condition of speciﬁ c antilock components is provided to the mechanic by a series of labeled, light emitting diodes (LED’s) displayed through a “window” in the EC-15™ controller housing. No special tools or equipment are needed to read or interpret the EC-15™ controller diagnostics window. It should be noted that the EC-15™ controller diagnostics display is separate from the antilock condition lamp on the dash. With this separation, the driver is aware of any problems that occur but is not confused by the diagnostic information. A special feature of the EC-15™ controller is the failure latching and diagnostic system. Intermittent problems, particularly in the wheel speed sensing area can be difﬁ cult to diagnose. When the controller senses an erroneous condition, whether in the controller electronics, the modulator or wheel speed sensing areas, it stores the condition in non-volatile memory, disables the antilock function, illuminates the dash mounted antilock condition lamp and the appropriate diagnostic LEDs on the EC-15™ controller.

The failure condition is truly stored and is not cleared by loss of power to the EC-15™ controller. The LEDs will re-light when power is restored and remain illuminated until the failure is corrected. After the actual problem is corrected, maintenance personnel can clear or reset the

™

EC-15 over the RESET point in the diagnostics window.

DIAGNOSTIC LEDs

There are nine LEDs plus a magnetically actuated reset switch in the EC-15 ﬁ rst ﬁ ve LEDs locate a problem to a speciﬁ c area of the vehicle while the last four indicate the problem component or its wiring. The LEDs are software driven and are either ON or OFF depending upon their monitor function. (Note: Right and left, front and rear are determined from the driver’s seat. Left front is therefore the corner closest to the driver.)

controller diagnostics by passing a small magnet

™

controller diagnostic window. The

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LED o FRONT Red LED LED o MID Red LED (SEE NOTE BELOW) LED o REAR Red LED LED o RIGHT Red LED LED o LEFT Red LED LED o MOD Red LED LED o SENS Red LED LED o ECU Red LED LED o VOLT Green LED III RESET No LED

NOTE: The MID LED shown in the chart above is not used

™

in the diagnostic process for the EC-15

controller however it will light when a magnet is placed on the RESET switch in the diagnostic window.

“LEFT” LED This Red LED illuminates and latches ON in order to

indicate the location of a problem component or its wiring. It will light in conjunction with either the FRONT or REAR LED and the MOD or SENS LED.

“MOD” LED This Red LED illuminates and latches ON to indicate

a permanent or intermittent open or short circuit in the solenoids of one of the four modulators or the wiring connecting it to the system.

“SENS” LED

FRONT

MID

REAR

RIGHT

LEFT MOD

SENS

ECU

VOLT

RESET

EC-15™ CONTROLLER

DIAGNOSTIC WINDOW

“FRONT” LED This Red LED illuminates and latches ON in order to

indicate the location of a problem component or its wiring. It will light in conjunction with either the RIGHT or LEFT LED and the MOD or SENS LED.

“MID” LED This Red LED is not used in troubleshooting the EC-15

controller and should light only when a magnet is held on the RESET switch.

™

This Red LED illuminates and latches ON to indicate permanent or intermittent failure. The failures indicated are; open or shorted wheel speed sensor, open or shorted wheel speed sensor wiring, wheel speed signal not present or does not conform to design criteria.

“ECU” LED This Red LED, when illuminated, indicates that the

controller itself has failed. It is latched ON for all EC-15 controller failures except low voltage. For voltages less than 9VDC, the LED illuminates to indicate the controller is inoperative, however when the voltage again exceeds 9VDC the LED will go OUT by itself.

“VOLT” LED This Green LED illuminates and remains ON during

vehicle operation to indicate that vehicle power is reaching the controller. If vehicle power is out of range for proper operation (below 1 1 vdc or above 17 vdc) this LED will ﬂ ash until power is brought into range.

“RESET” Beneath the RESET area of the window display is a

magnetically sensitive switch that is used to reset the diagnostic system. The device will respond to a magnet which has strength sufﬁ cient to lift a three (3) ounce weight. Holding a magnet against the RESET will cause all LEDs to light during the time the magnet is against it.

™

“REAR” LED This Red LED illuminates and latches ON in order to

indicate the location of a problem component or its wiring. It will light in conjunction with either the RIGHT or LEFT LED and the MOD or SENS LED.

“RIGHT” LED This Red LED illuminates and latches ON in order to

indicate the location of a problem component or its wiring. It will light in conjunction with either the FRONT or REAR LED and the MOD or SENS LED.

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TROUBLESHOOTING

GENERAL

While the EC-15™ controller diagnostic display locates a speciﬁ c problem area, it is still necessary to conﬁ rm whether the problem resides in the component itself or the wiring. Basically the troubleshooting procedure that follows is devoted to narrowing the problem to either the wiring or a speciﬁ c antilock component.

TROUBLESHOOTING TIPS

1. All troubleshooting begins by observing the antilock condition lamp on the dash. Troubleshooting should begin by ﬁ rst performing the “Initial Start-up Procedure” and following the directions contains in it.

2. The troubleshooting technician should record all ﬁ ndings and the action taken during the troubleshooting process.

3. No voltage or resistance tests are performed into the EC-15™ controller. All voltage and resistance tests are performed by beginning at the wire harness half of the connector and moving AWAY from the EC-15™ controller toward an antilock system component (modulator, wheel speed sensor, etc.)

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START HERE

TROUBLESHOOTING

INITIAL START-UP PROCEDURE

TURN VEHICLE IGNITION ON. OBSERVE DASH ANTILOCK CONDITION LAMP.

IS DASH LAMP ILLUMINATED?

YES

DASH LAMP DOES NOT BLINK, IT COMES ON AND REMAINS ON.

DASH LAMP FLASHES AND COMES ON AND STAYS ON. INCREASE VEHICLE SPEED TO ABOVE 10 MPH FOR AT LEAST 30 SECONDS AND OBSERVE THE DASH LAMP.

YES

GO TO SECTION I “DASH LAMP TESTING”

GO TO SECTION II “INSPECTION FOR ILLUMINATED LED(S)”

YES

DASH LAMP REMAINS ON

THE SYSTEM IS FUNCTIONING NORMALLY. MAKE NOTES OF THE PARTS REPLACED OR REPAIRED AND STEPS TAKEN ON THE TROUBLE SHOOTING SHEET.

GO TO SECTION III “INSPECTION FOR ILLUMINATED LED(S)”.

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START HERE

TROUBLESHOOTING

SECTION I - DASH LAMP TESTING

DISCONNECT WIRE HARNESS CONNECTOR FROM EC-15™ CONTROLLER (FRONT CONNECTOR ONL Y IN FIGURE 7) AND OBSERVE THE DASH LAMP.

DASH LAMP ILLUMINATED?

YES

WITH IGNITION ON, MEASURE VOLTAGE BETWEEN LAMP RELAY AND GROUND. VOLTAGE SHOULD BE SAME AS BATTERY VOLTAGE (SEE FIGURES 7 AND 8)

IS VOLTAGE CORRECT?

YES

REPLACE THE EC-15™ CONTROLLER

REPLACE FUSE AND/OR REPAIR OR REPLACE WIRE HARNESS

CHECK WIRING HARNESS AND RELAY FOR SHORTS TO GROUND. RECONNECT AND CHECK/REPLACE THE FOLLOWING:

1. DASH LIGHT BULB

2. RELAY POWER WIRE

3. RELAY AFTER REPLACING EACH COMPONENT TEST THE DASH LAMP

REPEA T THE “INITIAL START-UP PROCEDURE”.

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SECTION II - INSPECTION FOR ILLUMINATED LEDS

START HERE

TROUBLESHOOTING

INSPECT EC-15™ CONTROLLER FOR PRESENCE OF ILLUMINATED LEDS AND RECORD.

ARE ANY RED LEDS ILLUMINATED?

YES

NOTE AND RECORD THE CONDITION OF ALL RED LEDS

CHECK CLOSELY AND NOTE IF GREEN LED IS ILLUMINATED

ARE ANY

YES (ON)

RED LED’S ILLUMINATED?

IS GREEN LED FLASHING?

YES

GO TO SECTION V “TESTING FOR POWER TO THE EC-15™ CONTROLLER”.

NO (OFF)

YES

REPLACE

THE EC-15™

CONTROLLER

GO TO SECTION V “TESTING FOR POWER TO THE

™

EC-15

CONTROLLER”

GO TO SECTION IV “INSPECTION FOR ILLUMINATED LEDS”.

GO TO SECTION VIII “TESTING FOR FALSE FAILURE INDICATION - CAUSED BY DASH LAMP RELAY”.

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START HERE

TROUBLESHOOTING

SECTION III - INSPECTION FOR ILLUMINATED LED’S

INSPECT THE EC-15™ CONTROLLER FOR PRESENCE OF ILLUMINATED LEDS AND RECORD.

GO TO SECTION V “TESTING FOR POWER

™

TO THE EC-15 CONTROLLER”.

YES

IS GREEN, VOLT, LED ILLUMINATED?

YES

IS GREEN LED FLASHING?

ARE ANY RED LEDS ILLUMINATED?

YES

ARE ANY RED LED’S ILLUMINATED?

REPLACE THE

EC-15™ CONTROLLER

GO TO SECTION IX “TESTING FOR FALSE FAILURE INDICATION - CAUSED BY WHEEL SPEED COMPONENTS”.

YES

GO TO SECTION

V “TESTING FOR POWER TO THE EC-15™ CONTROLLER”.

NOTE AND RECORD THE CONDITION OF ALL RED LEDS

GO TO SECTION IV “INSPECTION FOR ILLUMINATED LEDS”.

Page 17

TROUBLESHOOTING

SECTION IV - INSPECTION FOR ILLUMINATED LEDS.

START HERE

NOTE RED “ECU” LED IN

™

EC-15

CONTROLLER

DIAGNOSTICS WINDOW.

IS THIS LED ILLUMINATED?

THERE MUST BE A MINIMUM OF THREE RED LEDS ILLUMINATED AND OF THE THREE THERE MUST BE A “RIGHT” OR “LEFT”, PLUS A “FRONT” OR “REAR”, PLUS A “MOD” OR “SENS”.

DO THE ABOVE CONDITIONS EXIST?

YES

GO TO SECTION V “TESTING FOR POWER TO THE EC-15™ CONTROLLER”.

REPLACE THE EC-15™ CONTROLLER AND REPEAT THE “INITIAL START-UP PROCEDURE”.

YES

NOTE THE THREE ILLUMINATED LEDS.

IS “MOD” LED ILLUMINATED

THE “SENS” LED IS ILLUMINATED

USING THE TWO POSITIONING LEDS (RIGHT/LEFT FRONT/REAR) GO TO SECTION VIIA “TESTING THE WHEEL SPEED SENSOR” AND TEST THE APPROPRIATE SPEED SENSOR.

YES

USING THE TWO POSITIONING LED’S (RIGHT/LEFT FRONT/REAR) GO TO SECTION VIA “TESTING THE MODULATOR” AND TEST THE APPROPRIATE MODULATOR.

Page 18

START HERE

TROUBLESHOOTING

SECTION V - TESTING FOR POWER TO THE EC-15™ CONTROLLER

TURN IGNITION OFF, REFER TO FIGURES 7 AND 8, DISCONNECT WIRE HARNESS CONNECTOR FROM EC-15™ CONTROLLER (FRONT CONNECTOR ONLY IN FIGURE 7)

TURN IGNITION ON AND, MEASURE VOLTAGE BETWEEN BATTERY AND GROUND PINS ON WIRE HARNESS CONNECTOR (SEE FIGURES 7 AND 8).

VOLTAGE SAME AS BATTERY VOLTAGE, MUST BE BETWEEN 11 AND 17 VOLTS.

YES

REPLACE EC-15™

CONTROLLER

RECONNECT CONNECTOR TO EC-15™ CONTROLLER. CHECK THE VEHICLE WIRING FOR CONTINUITY. REFER TO THE VEHICLE SERVICE MANUAL AND CHECK THE BATTERY VOLTAGE. REPAIR OR REPLACE AS NECESSARY AND REPEAT THE “INITIAL START-UP PROCEDURE”

REPEA T THE “INITIAL START-UP PROCEDURE”

Page 19

TROUBLESHOOTING

SECTION VI A - TESTING THE MODULATOR

TURN IGNITION OFF. REFER TO FIGURES 7 AND 8. DISCONNECT WIRE HARNESS CONNECTOR FROM EC-15™ CONTROLLER.

PROBE CONNECTOR WITH VOLT/OHM METER AND NOTE THAT PROPER RESISTANCE VALUES ARE OBTAINED FOR MODULATOR BEING TESTED. FIGS. 7 AND 8. RESISTANCE VALUES HERE FOR BENDIX® M-21™ MODULATOR (FIG. 5). HOLD TO SOURCE: READ 3.5 TO 5 OHMS EXHAUST TO SOURCE: READ 3.5 TO 5 OHMS EXHAUST TO HOLD: READ 7 TO 10 OHMS SOURCE TO BATTERY POWER: NO CONTINUITY SOURCE TO GROUND: NO CONTINUITY

NOTE: SOURCE TO BATTERY TEST NOT REQUIRED FOR CONNECTOR 2, (REAR) DEUTSCH CONNECTOR FIGURE 7.

START HERE

ARE RESISTANCE VALUES CORRECT?

GO TO SECTION VI B AND

CONTINUE TESTING

YES

INSPECT CONNECTOR AND RECONNECT TO EC-15™ CONTROLLER. TURN IGNITION ON AND PASS MAGNET OVER RESET ON EC-15™ CONTROLLER. NOTE REACTION OF RED LEDS.

REPEAT “INITIAL START-

ARE ANY RED LED’S

ILLUMINATED?

SAME RED LED’S

ILLUMINATED?

GO TO SECTION IV

“INSPECTION FOR ILLUMINATED RED

LEDS” AND RETEST.

UP PROCEDURE”. IF THIS TEST STEP HAS REPEATED TWICE - REPLACE THE

EC-15™ CONTROLLER.

FRONT OR REAR

MODULATOR?

TEST REAR MODULATOR ON OPPOSITE SIDE OF VEHICLE

GO TO BEGINNING THIS

SECTION (VI) AND RETEST

REPLACE EC-15™ CONTROLLER

IF FAILURE PERSISTS, REPLACE THE EC-15™ CONTROLLER.

Page 20

START HERE FROM

SECTION VI A

TROUBLESHOOTING

SECTION VI B - TESTING THE MODULATOR

GO TO MODULATOR, INSPECT WIRING CONNECTOR. DISCONNECT CONNECTOR AND TEST RESISTANCE BETWEEN PINS ON MODULATOR, RESISTANCE VALUES FOR BENDIX HOLD TO SOURCE: READ 3.5 TO 5 OHMS EXHAUST TO SOURCE: READ 3.5 TO 5 OHMS EXHAUST TO HOLD: READ 7 TO 10 OHMS TEST EACH PIN TO VEHICLE GROUND AND NOTE NO CONTINUITY.

M-21™ MODULATOR (FIGURE 5).

RESISTANCE READINGS

CORRECT?

YES

RECONNECT CONNECTOR TO MODULATOR. TURN IGNITION ON AND PASS MAGNET OVER RESET ON EC-15™ CONTROLLER. NOTE REACTION OF RED LEDS.

ARE ANY RED LED’S

ILLUMINATED?

YES

REPLACE THE MODULAT OR

REPEA T THE “INITIAL

START-UP PROCEDURE”

SAME RED LED’S

YES

ILLUMINATED?

GO TO SECTION IV “INSPECTION FOR

ILLUMINATED LEDS” AND RETEST.

REPAIR OR REPLACE

MODULATOR WIRE HARNESS.

Page 21

TROUBLESHOOTING

SECTION VII PART A - TESTING THE WHEEL SPEED SENSOR

START HERE

IGNITION ON, NOTE ILLUMINATED LED’S ON LOG SHEET.

DO MAGNETIC RESET, NOTE REACTION OF RED LED’S.

2ND TIME TO THIS POINT

YES

DURING TESTING?

SAME RED

AND RED LED’S ON?

YES

LED’S ON?

YES

GO TO SECTION VII PART

B AND BEGIN TESTING

TURN IGNITION OFF AND CHECK FOLLOWING: A.

REMOVE CONNECTOR(S) FROM EC-15™ CONTROLLER AND MEASURE RESISTANCE BETWEEN APPROPRIATE SPEED SENSOR SIGNAL (+) AND SIGNAL RETURN (-). RESISTANCE FOR BENDIX® WS-20™ SPEED SENSOR IS BETWEEN 1500-2500 CHMS. REFER TO VEHICLE MAINTENANCE MANUAL IF OTHER THAN THE WS-20™ SPEED SENSOR IS IN USE. (REFER FIG.8) IF RESISTANCE NOT CORRECT, DISCONNECT CONNECTOR AT SPEED SENSOR. INSPECT CONNECTOR, THEN CHECK RESISTANCE BETWEEN PINS ON SENSOR. IF RESISTANCE IS NOT CORRECT (BETWEEN 1500-2500 OHMS FOR THE BENDIX® WS-20™ SPEED SENSOR), REPLACE SENSOR, OTHERWISE PROCEED TO STEP B.

B. CHECK “GAP” BETWEEN SPEED SENSOR AND EXCITER OR TONE RING. (GAP

FOR BENDIX® WS-20™ SPEED SENSOR, SPEED SENDER IS BETWEEN 0 - .015 INCHES) IF SENSOR GAP MUST BE ADJUSTED, CHECK FOR LOOSE OR WORN WHEEL BEARINGS BEFORE RE-GAPPING SENSOR. REFER TO VEHICLE MAINTENANCE MANUAL FOR WORN BEARINGS.

C. IF SENSOR GAP IS CORRECT CHECK WHEEL BEARING FOR FREE PLAY TO

VERIFY IT COMPLIES TO MANUFACTURER’S RECOMMENDATIONS.

D. MAKE CERTAIN EXCITER OR TONE RING IS IN PLACE AND INSPECT CONDITION.

CHECK FOR MISSING OR DAMAGED TEETH AND THAT IT RUNS TRUE AND

PERPENDICULAR TO SENSOR FACE. E. CHECK WIRING HARNESS AND CONNECTORS THAT RUN TO SENSOR. F. CHECK FOR DRAGGING BRAKES (OVER ADJUSTED, TRAPPED AIR IN

ACTUATOR, OUT OF ROUND DRUMS, FAULTY RETURN SPRINGS, PARKING

BRAKE SYSTEM FAULTS, ETC.) AND CORRECT AND RETEST.

GO TO SECTION VII PART

B AND BEGIN TESTING

GO TO SECTION IV

RECONNECT CONNECTORS AT EC-15

™

CONTROLLER AND SPEED SENSOR, DO MAGNETIC

RESET. NOTE RED LED’S.

ARE ANY RED LED’S ILLUMINATED?

YES

GO TO “INITIAL START-UP PROCEDURE”

GO TO SECTION III

- “INSPECTION FOR ILLUMINATED LED’S.”

Page 22

TROUBLESHOOTING

SECTION VI PART B - TESTING THE WHEEL SPEED SENSOR

START HERE FROM

SECTION VII P ART A

IGNITION OFF. REMOVE CONNECTOR(S) FROM EC-15™ CONTROLLER. MEASURE RESISTANCE BETWEEN THE APPROPRIATE SPEED SIGNAL (+) AND SIGNAL RETURN (-). RESISTANCE FOR BENDIX® WS-20™ SENSOR IS BETWEEN 1500-2500 OHMS. REFER TO VEHICLE MANUAL FOR THE RESISTANCE VALUES IF OTHER THAN WS-20™ SENSOR IS IN USE. (REFER TO FIGURE 7 & 8)

SAME LED’S ILLUMINATED?

YES

CORRECT RESISTANCE?

GO TO SECTION III “INSPECTION

FOR ILLUMINATED LEDS”.

YES

REPLACE EC-15™ CONTROLLER

DISCONNECT CONNECTOR AT SPEED SENSOR INSPECT THE CONNECTOR, THEN CHECK THE RESISTANCE BETWEEN TWO PINS ON SENSOR. RESISTANCE BETWEEN 1500-2500 OHMS FOR THE BENDIX® WS-20™ SPEED SENSOR.

YES

RECONNECT CONNECTOR AT SPEED

SENSOR AND EC-15™ CONTROLLER

AND DO MAGNETIC RESET. NOTE IF

ANY RED LEDS ARE ILLUMINATED.

ARE ANY LED’S ILLUMINATED?

YES

ARE SAME RED LED’S ILLUMINATED?

REPLACE THE SENSOR

REPEA T THE “INITIAL

START-UP PROCEDURE”

GO TO SECTION III “INSPECTION

FOR ILLUMINATED LEDS”

YES

REPAIR OR REPLACE SPEED

SENSOR WIRING HARNESS.

Page 23

TROUBLESHOOTING

SECTION VIII - TESTING FOR FALSE INDICATION CAUSED BY DASH LIGHT RELAY

START HERE

TESTING THE LAMP RELAY

GROUND THIS WIRE AT EC-15™ CONTROLLER CONNECTOR

TO EC-15

™

CONTROLLER CONNECTOR

LAMP

HOLD A MAGNET ON EC-15™ CONTROLLER RESET AND NOTE ALL LEDS ILLUMINATED

ARE ALL LEDS ILLUMINATED?

YES

REMOVE MAGNET FROM EC-15™ CONTROLLER, TURN IGNITION OFF AND DISCONNECT THE WIRING HARNESS CONNECTOR(S) FROM EC-15™ CONTROLLER. TURN IGNITION ON, GROUND LAMP RELAY WIRE (PIN 1K FIG. 7) (PIN 3F FIG.8) AND NOTE DASH LAMP REACTION.

RELAY

DASH LAMP OFF?

YES

REPLACE EC-15™ CONTROLLER

LAMP ON

CONTINUE

TESTING

TESTING THE LAMP RELAY

TO EC-15™ CONTROLLER CONNECTOR

CHECK FOR POWER HERE

TURN IGNITION OFF AND CHECK CONTINUITY OF WIRING LAMP WIRE BETWEEN EC-15™ CONTROLLER WIRING HARNESS CONNECTOR (SEE FIG. 7 & 8) AND TERMINAL ON LAMP RELAY.

IS CONTINUITY DETECTED?

YES

RECONNECT THE EC-15™ CONTROLLER WIRE HARNESS CONNECTOR(S), AND CHECK FOR VEHICLE POWER AT THE LAMP RELAY COIL.

RELAY

IS POWER DETECTED?

LAMP

YES

REPAIR OR REPLACE WIRE HARNESS. RECONNECT EC-15™ CONTROLLER WIRE HARNESS AND REPEAT THE “INITIAL STARTUP PROCEDURE”

CHECK DASH WIRING AND CONNECTORS, AND CONSULT THE VEHICLE MANUAL FOR TROUBLE SHOOTING INFORMATION. REPAIR OR REPLACE AS NECESSARY AND REPEAT THE “INITIAL START-UP PROCEDURE”.

LAMP ON

BAD RELAY

REPLACE THE RELAY AND REPEAT

THE “INITIAL START-UP PROCEDURE”

Page 24

SECTION IX - TESTING FOR FALSE INDICATION CAUSED BY WHEEL SPEED COMPONENTS

START HERE

TROUBLESHOOTING

HOLD A MAGNET ON RESET OF EC-15™ CONTROLLER AND NOTE LEDS

ARE ALL LEDS ILLUMINATED?

YES

REMOVE MAGNET

TURN IGNITION OFF AND INSPECT APPROPRIA TE AXLE AND WHEEL FOR PRESENCE OF AN EXCITER OR TONE RING AND SPEED SENSOR. CHECK THE SENSOR “GAP” (DISTANCE BETWEEN SPEED SENSOR AND EXCITER RING) AND BEARING END PLAY. RE-ADJUST AS NECESSARY.

REPLACE EC-15™ CONTROLLER

RUN VEHICLE AT 10 MPH OR MORE FOR 30 SECONDS OR MORE. TURN

OFF IGNITION

REPEAT “INITIAL START-UP

PROCEDURE”